Graco BetaCell 241D Instruction Manual

Operation
BetaCell 241D
Metering Unit
3A0258A
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.

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Contents
GENERAL SAFETY INFORMATION ....................................................................................................... 4
Acceptable Equipment Uses..................................................................................................................... 4
OPERATIONAL SAFETY PROCEDURES............................................................................................... 5
General Description.............................................................................................................................. 6
Specifications............................................................................................................................................ 8
System Dimensions.............................................................................................................................. 8
Metering Unit ........................................................................................................................................ 9
Hydraulic Power Pack .......................................................................................................................... 9
Buffer tanks .......................................................................................................................................... 9
Factory Settings-Metering Unit........................................................................................................... 10
Factory Settings-Hydraulic Power Pack ............................................................................................. 10
Dry Air or Nitrogen.............................................................................................................................. 10
DESCRIPTION OF CONTROLS ............................................................................................................ 11
Main Electric Panel ................................................................................................................................. 12
Main Menu Screen.................................................................................................................................. 14
Help Screen ............................................................................................................................................ 15
Status Screen ......................................................................................................................................... 16
Machine Control Screen ......................................................................................................................... 18
Tank Control Screen............................................................................................................................... 20
Operator Screen ..................................................................................................................................... 22
Maintenance Menu ............................................................................................................................. 24
Maintenance Screen........................................................................................................................... 25
Flow Control Screen ............................................................................................................................... 27
Sequence Entry Screen ..................................................................................................................... 28
AutoStart Set-Up Screen.................................................................................................................... 30
Sleep Mode Set-Up Screen................................................................................................................ 31
Pre Poly Refresh Set-Up Screen........................................................................................................ 32
Flow Control Screen ........................................................................................................................... 33
Shot Calibration Screen ..................................................................................................................... 34
Tolerance Setup Screen..................................................................................................................... 35
DESCRIPTION OF MAJOR COMPONENTS......................................................................................... 37
System Schematic .................................................................................................................................. 38
Overview ................................................................................................................................................. 39
Buffer tanks ........................................................................................................................................ 39
Metering.............................................................................................................................................. 40
Pre-Heaters ........................................................................................................................................ 40
Transducers........................................................................................................................................ 41
Recirculation....................................................................................................................................... 41
Pour Gun ............................................................................................................................................ 41
Hydraulic Power Pack ........................................................................................................................ 41
Pneumatic System .................................................................................................................................. 42
Buffer tank Pressurization Valves ...................................................................................................... 42
Air Regulator....................................................................................................................................... 43
Buffer tank............................................................................................................................................... 44
Jacket Heater ..................................................................................................................................... 47
Mixer ................................................................................................................................................... 48
Buffer tank Pressure Relief Valve ...................................................................................................... 49
Buffer tank Safety Relief Valve........................................................................................................... 50
Return Line Check Valve.................................................................................................................... 51
AutoFill System ....................................................................................................................................... 52
Magnetic Liquid Level Indicator.......................................................................................................... 52
AutoFill Valve .......................................................................................................................................... 55
Inlet Safety Valve .................................................................................................................................... 56
Operation............................................................................................................................................ 56

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Maintenance ....................................................................................................................................... 56
Metering Pump Inlet Filter....................................................................................................................... 57
Metering System ..................................................................................................................................... 58
Pre-Polymer Pump ............................................................................................................................. 58
Curative Pump.................................................................................................................................... 59
Pressure Transducer .............................................................................................................................. 60
Pre-Heaters............................................................................................................................................. 61
Flow Meters ............................................................................................................................................ 62
Recirculation Valve............................................................................................................................. 63
Control Valve ...................................................................................................................................... 64
Hydraulic Power Pack............................................................................................................................. 65
Schematic........................................................................................................................................... 65
Overview............................................................................................................................................. 66
Power Pack ........................................................................................................................................ 68
Hydraulic Fluid.................................................................................................................................... 69
Unloading Valve ................................................................................................................................. 70
Accumulator........................................................................................................................................ 71
Manual Unloading Valve .................................................................................................................... 72
Directional Valve................................................................................................................................. 72
Return Line Filter ................................................................................................................................ 73
INSTALLATION & SET-UP..................................................................................................................... 74
Installation............................................................................................................................................... 75
Hoses ................................................................................................................................................. 76
Buffer tanks ........................................................................................................................................ 77
Hydraulic System................................................................................................................................ 77
DAILY PROCEDURES ........................................................................................................................... 78
Daily Start-Up.......................................................................................................................................... 79
Daily Shutdown ....................................................................................................................................... 79
FAULT MANAGEMENT.......................................................................................................................... 80
Alarm system .......................................................................................................................................... 81
Alarm Status Screen........................................................................................................................... 81
Alarm History Screen.......................................................................................................................... 82
Alarm Alerts ........................................................................................................................................ 82
Warning and Fault Messages............................................................................................................. 83
MAINTENANCE...................................................................................................................................... 88
BetaCell 241 Maintenance Procedure.................................................................................................... 89
BetaCell 241 Preventative Maintenance Schedule .............................................................................. 100
BetaCell 241Preventative Maintenance Procedures ............................................................................ 102
Graco Ohio Standard Warranty ............................................................................................................ 110
Graco Ohio Information ........................................................................................................................ 110

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GENERAL SAFETY INFORMATION
It is necessary to understand and follow the instructions in this manual to
insure proper and safe operation of the equipment.
As with most mechanical equipment, certain safety precautions must be
taken when the equipment discussed in this manual is operated or
serviced. Severe bodily injury or damage to equipment and property may
result if the instructions and precautions listed throughout this manual are
not followed.
Needless to say, sufficient guidelines cannot be developed to eliminate the
need for good common sense in the use and servicing of this equipment,
and in the use and application of the products this equipment has been
designed to process. Users of this equipment must therefore make their
own determination as to the suitability of the information contained in this
manual to their specific operation and requirements. There should be no
assumption made that the safety measures and instructions contained
herein are all-inclusive, and that other safety measures may not be
required for specific use or application.
The following safety guidelines are generally applicable to the safe and
efficient use of the equipment.
Acceptable Equipment Uses
The equipment is designed for the dispensing of polyurethane foams.
Under no circumstances should any acid or corrosive chemicals be used in
the unit. Consult GUSMER if there is any doubt about the compatibility
of the chemical system to be used in this equipment.
Any use of this equipment other than as indicated above constitutes
misuse unless express written approval is obtained from GUSMER.

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OPERATIONAL SAFETY PROCEDURES
This safety information will not be repeated in the text of this manual.
The symbols pertaining to this information will appear where appropriate
to alert the operator to potential hazards.
Solvents and Chemicals
WARNING: The solvents and chemicals used with this equipment expose
the operator to certain hazards. Adequate personal protective measures
must be taken so as to avoid exceeding the Threshold Limit Value (TLV)
of the products being used, as established by the Occupational Safety and
Health Administration (OSHA) or other qualified agency. Information
concerning personal protection and proper handling should be obtained
from the supplier of such chemicals.
High Voltage
WARNING: To prevent serious bodily injury from electrical shock, never
open the electric panels or otherwise service this equipment and/or
equipment used with it before switching off the main power disconnect
and interrupting supply voltage at the source. The electrical service must
be installed and maintained by a qualified electrician.
High Pressure
WARNING: This equipment has or is used with equipment that has
hydraulic components capable of producing up to 3500 psi. To avoid
serious bodily injury from hydraulic injection of fluid, never open any
hydraulic connections or service hydraulic components without bleeding
all pressures to zero.
Personal Protective
Equipment
WARNING: To avoid serious bodily injury, proper protective gear must
be worn when operating, servicing, or being present in the operational
zone of this equipment. This includes, but is not limited to, eye and face
protection, gloves, safety shoes, and respiratory equipment as required.
High Temperature
WARNING: This equipment has or is used with equipment that has high
temperature components such as primary heaters and heated hoses. To
prevent serious bodily injury from hot fluid or hot metal, never attempt to
service the equipment before allowing it to cool.
Warning
WARNING: Failure to read and follow this safety information may result
in personal injury and/or damage to the equipment from one or more of
the above listed hazards

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General Description
The Gusmer BetaCell 24:1 machine is manufactured to operate on 460V 3. 60 Hz electrical
service with a current draw of approximately 100 amps.
The operation of the machine combined with processing of the chemicals require
precautionary measures described in the maintenance/operator's manual.
The principle of operation is that two Gusmer pumps, one for Curative, and the other for
Prepoly, deliver chemicals to a dispensing gun at the foam application station in a circulating
manner. Initiating the dispensing of the foam is under the operator's control. Deactivating a
safety by use of a double trigger pull allows the operator to commence a shot, which causes the
gun to open and foam to be dispensed. The quantity of foam
dispensed is controlled either by the operator’s release of the trigger or the control system’s
completion of the desired shot size.
Shot sizes and sequences are programmable by qualified technicians and are openly displayed to
the operator on his/her operator screen.
Temperature control of the chemicals is maintained by setting the individual digital
controls within the PLC. The new circulation system ensures constant and accurate temperature
control.
PID programming of the temperature controllers allows operation within a given
temperature range. Operation outside the designated range activates alarms and could
include simultaneous shutdown of the machine.
The machine has one FVD driven pump and one linear drive pump, each with their own flow
meter control loop. This ensures extremely accurate flow rates and therefore ratio control.
While in the non-dispensing mode, chemicals in the metering machine are constantly circulating
through the orifices in the head. This not only keeps the orifices clean, but also ensures constant
flow and temperature control. This feature of the
design also allows for elimination the requirement for high maintenance heated hoses.
Pressure transducers also feed information to the PLC. The software program within the
PLC allows operation of the machine within a given pressure range, the operation within
a wider pressure range will activate a high pressure alarm with potential simultaneous
shut down of the machine.
The Gusmer equipment includes Buffer tanks, which act as on board chemical reservoirs. These
tanks are temperature and pressure maintained and includes agitation to ensure product quality.
Material is fed into the Buffer tanks via the chemical feed system header.

Specifications
System Dimensions
54
108
98 3
/
16

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Metering Unit
Electric 63.3 FLA amps@ 3 x 460 volts; 60 Hz
A-motor 5 hp vector
B-motor 1 hp servo
Max pressure 1500 psi
Max oper pres 1200 psi
Max output 15 lbs/min (110 cc/sec)
Hydraulic Power Pack
Motor 5 hp
Flow rate 6 cc/rev (3 gpm)
Max pressure 3000 psi
Max oper pres 2800 psi
Max temp 160ºF
Reservoir 8 gal
Accumulator 85 cu in
Min cycle time 3 sec
Buffer tanks
Construction • Pre Poly: steel ASME certified
• Curative: stainless steel, ASME certified
Chemical Capacity • Pre-Polymer – 20 gallons useable
• Curative – 10 gallons useable
Oil Jacket • Pre Poly-15 gallons
• Curative – 7.5 gallons
Mixer • 29 RPM
Max Pressure • 100 psi
Max temperature • 180°F

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Factory Settings-Metering Unit
Max pressure sw 1500 psi
Min pressure sw 40 psi
Factory Settings-Hydraulic Power Pack
Max pressure sw 2800 psi
Min pres sw 1500 psi
Acum. Pre charge 1200 psi
Unload vlv-upper 2400 psi
Unload vlv-lower 2200 psi
Dry Air or Nitrogen
100-120 psi

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DESCRIPTION OF CONTROLS
1

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Main Electric Panel
Push to silence audible alarm
White pilot light indicates that PLC power is ON
White pilot light indicates that auxiliary 115 volt outlets are ON

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Emergency Stop: interrupts control power
Master Start: Turns ON control power; green pilot light indicates that
control power is ON
Typical Motor Start: momentary start to turn motor ON. Switch must be in
the RUN position to start the motor from the HMI panel; green pilot
indicates that the motor is ON
Hour Meter

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Main Menu Screen
The Main Menu Screen permits selection of each of the screens indicated in
the picture above by pressing the touch screen buttons.
Restricted
Access
The Maintenance Menu is for qualified technicians and can only be
accessed by password.
IMPORTANT • This manual describes two chemical components: the Pre-Polymer (A)
and the Curative (B). The HMI Screens follow the convention A and B
to delineate the switches for each component.
• This Manual generally describes the function of the Acontrols only.
The function of the Bcontrols is identical except where noted.

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Help Screen
A Help Screen is available for each of the Menu Screens.

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Status Screen
All data windows are viewed in real time
Pilot light convention • Green pilot light indicates that a particular component is ON or set
for normal operation.
• A blue pilot indicates that a component is OFF
• A yellow pilot light indicate that a component is not set for normal
operation
• SP windows display the set points of a component. PV data
windows display the actual process variable of a component.

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• MAN: Depress the trigger and hold; the shot will continue as long
as the trigger is held
• AUTO: momentarily trigger the gun and release. The shot will
continue automatically until the preset shot size is completed;
yellow indicates MAN and green pilot light indicates AUTO
• GO/NOGO: green pilot indicates that the gun is GO for dispense.
Red pilot light indicates NOGO
NOTE: A GO signal is
possible with ratio
control in MAN if the
tolerance limits are
DISABLED
The following conditions must be satisfied for a GO signal:
• No active faults
• A & B pumps ON
• Recirculation valves CLSD
• Ratio control in AUTO
• Hydraulic pressure above 1500 psi
• T-T set point has timed out between shots
• Gun service switch OFF
• Pre set tolerance limits satisfied
• AutoStart or sleep mode DEACTIVATED
• Re set initiated after the 10th shot in a sequence is completed
• TRIG: green pilot light indicated the gun trigger is depressed
• CLSD: blue pilot light indicates that the gun is CLSD; green pilot
indicated that the gun is OPEN
• Indicates the fault condition

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Machine Control Screen
• Press to turn ON and OFF the pump; pilot light indicates the
state
• Data windows indicate the PV’s
NOTE: • Each time the Pre Poly pump is turned OFF; it will default to
50 RPM and flow control to MAN
• Curative default is ½ inches per second
• Press the set point data window, a keypad will appear; select
the temperature and press enter

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AutoStart
• Press to ON; automatically starts the machine in a
preprogrammed sequence. Once started, select the Status
Screen to monitor progress of the AutoStart
• AutoStart will not start if the Pre poly tank temperature is
below 95 deg F or the Curative is below 80 deg F
• The data window will record the elapsed time of the AutoStart
cycle
Sleep Mode
• Press to ON; automatically sets the machine to a pre set
operating condition as follows:
• Hydraulic motor OFF
• Pre Poly flow 30 grams/sec
• Curative 2 grams/sec
• Pre Poly heater 120 deg F
• Curative heater 95 deg F
Auto Shutdown
• Pres to shut off the operating components of the machine with
one selector switch
• Note: if the shutdown is not extended, it will be necessary to
restart the Pre Poly and Curative mixers and tank heaters to be
ready for the next AutoStart
Pilots lights indicate the component state

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Tank Control Screen
• Press to turn ON and OFF the motor; pilot light indicates
the state
• Press to turn ON and OFF the heater; pilot light indicates
the state
• Press the set point data window, a keypad will appear;
select the temperature and press enter
PV indicates the process temperature